Torque-equalizing fault response for electric vehicle

ABSTRACT

Various disclosed embodiments include illustrative controllers, dual power inverter modules, and electric vehicles. In an illustrative embodiment, a controller includes one or more processors associated with a first and second power inverter for the drive unit. Computer-readable media for the one or more processors are each configured to store computer-executable instructions configured to cause the one or more processors to apply a same fault action to the first power inverter and the second power inverter responsive to a fault associated with an inverter chosen from the first power inverter and the second power inverter, wherein the same fault action includes applying equalized torque to each axle operatively coupled to the drive unit.

INTRODUCTION

The present disclosure relates to inverters for drive units of electricvehicles. A conventional electric vehicle with two electric motors perdrive unit has two inverters (one inverter per motor) and each inverteris controlled by its own inverter controller. Use of a separate invertercontroller for each inverter adds weight and increases energyconsumption, thereby resulting in reduced vehicle range.

BRIEF SUMMARY

Various disclosed embodiments include illustrative controllers, dualpower inverter modules, and electric vehicles.

In an illustrative embodiment, a controller includes one or moreprocessors associated with a first and second power inverter for a driveunit for an electric vehicle. One or more computer-readable media forthe one or more processors are each configured to storecomputer-executable instructions configured to cause its associatedprocessor to apply a same fault action to the first power inverter andthe second power responsive to a fault associated with an inverterchosen from the first power inverter and the second power inverter,wherein the same fault action includes applying equalized torque to eachaxle operatively coupled to the drive unit.

In another illustrative embodiment, a dual power inverter moduleincludes a DC link capacitor electrically connectable to a source ofhigh voltage direct current (DC) electrical power. A first powerinverter is electrically connectable to the DC link capacitor and isconfigured to convert high voltage DC electrical power to three phasehigh voltage alternating current (AC) electrical power. The first powerinverter is further configured to supply the three phase high voltage ACelectrical power to a first electric motor. A second power inverter iselectrically connectable to the DC link capacitor and is configured toconvert high voltage DC electrical power to three phase high voltage ACelectrical power. The second power inverter is further configured tosupply the three phase high voltage AC electrical power to a secondelectric motor. A controller includes one or more processors associatedwith a first and second power inverter for a drive unit for an electricvehicle. One or more computer-readable media for the first processor andsecond computer-readable media are each configured to storecomputer-executable instructions configured to cause its associatedprocessor to apply a same fault action to the first power inverter andthe second power inverter responsive to a fault associated with aninverter chosen from the first power inverter and the second powerinverter, wherein the same fault action includes applying equalizedtorque to each axle operatively coupled to the drive unit.

In another illustrative embodiment, an electric vehicle includes avehicle body, a high voltage direct current (DC) electrical batterydisposed within the vehicle body, first and second (e.g., left andright) electric motors mechanically couplable to rotate at least one setof axles (e.g., coupled to wheels), and at least one dual power invertermodule. The at least one dual power inverter module includes: a DC linkcapacitor electrically connectable to the high voltage DC electricalbattery; a first power inverter electrically connectable to the DC linkcapacitor and configured to convert high voltage DC electrical power tothree phase high voltage alternating current (AC) electrical power, thefirst power inverter being further configured to supply the three phasehigh voltage AC electrical power to an electric motor chosen from firstand second (e.g., left and right) electric motors; a second powerinverter electrically connectable to the DC link capacitor andconfigured to convert high voltage DC electrical power to three phasehigh voltage AC electrical power, the second power inverter beingfurther configured to supply the three phase high voltage AC electricalpower to the other electric motor chosen from the left and rightelectric motors; and a common controller electrically connectable to thefirst power inverter and the second power inverter. The commoncontroller is configured to control the first power inverter and thesecond power inverter. The common controller includes one or moreprocessors associated with the first power inverter and the second powerinverter. One or more computer-readable media for the first processorand the second processor are each configured to storecomputer-executable instructions configured to cause its associatedprocessor to apply a same fault action to the first power inverter andthe second power inverter responsive to a fault associated with aninverter chosen from the first power inverter and the second powerinverter, wherein the same fault action includes applying equalizedtorque to each axle operatively coupled to the drive unit.

The foregoing summary is illustrative only and is not intended to be inany way limiting. In addition to the illustrative aspects, embodiments,and features described above, further aspects, embodiments, and featureswill become apparent by reference to the drawings and the followingdetailed description.

BRIEF DESCRIPTION OF THE DRAWINGS

Illustrative embodiments are illustrated in referenced figures of thedrawings. It is intended that the embodiments and figures disclosedherein are to be considered illustrative rather than restrictive.

FIG. 1A is a schematic illustration of an illustrative electric vehiclewith at least one drive unit.

FIG. 1B is a perspective view of lower body structure of the electricvehicle of FIG. 1 with illustrative drive units.

FIG. 2A is a perspective view of an illustrative drive unit of FIG. 1B.

FIG. 2B is another perspective view of the drive unit of FIG. 1B.

FIG. 2C is a side plan view of the drive unit of FIG. 1B.

FIG. 2D is an exploded perspective view of the drive unit of FIG. 1B.

FIG. 2E is a perspective view of another illustrative drive unit.

FIG. 3A is a block diagram in partial schematic form of an illustrativedual inverter with common control.

FIG. 3B is a perspective view of an illustrative dual inverter withcommon control.

FIG. 4A is a simplified schematic diagram of an illustrative dualinverter with a common DC link capacitor.

FIGS. 4B and 4C are graphs of ripple waveforms with no cancellation.

FIG. 4D is a flow chart of an illustrative method for synchronizingpulse width modulation clocks.

FIGS. 4E and 4F are graphs of illustrative ripple waveforms withcancellation.

FIG. 4G illustrates a look-up table.

FIG. 5A is a block diagram of illustrative components configured toplace both inverters of a drive unit in a safe state responsive to adetected fault associated with either inverter.

FIG. 5B is a graph of torque versus speed.

FIG. 5C is a block diagram of details of components of FIG. 5A.

FIG. 5D is a simplified schematic diagram of open upper and lower banksof three-terminal power semiconductor devices.

FIG. 5E is a simplified schematic diagram of a shorted lower bank ofthree-terminal power semiconductor devices.

FIG. 5F is a simplified schematic diagram of a shorted upper bank ofthree-terminal power semiconductor devices.

FIG. 5G is a flow chart of an illustrative method of placing bothinverters of a drive unit in a safe state responsive to a detected faultassociated with either inverter.

FIG. 6A is a schematic diagram of an illustrative circuit for detectingloss of low voltage DC electrical power.

FIG. 6B is a block diagram in partial schematic form of details of anillustrative backup circuit for providing low voltage DC electricalpower.

FIG. 6C is a flowchart of a method of placing both inverters of a driveunit in a safe state responsive to loss of low voltage DC electricalpower.

Like reference symbols in the various drawings generally indicate likeelements.

DETAILED DESCRIPTION

In the following detailed description, reference is made to theaccompanying drawings, which form a part hereof. In the drawings,similar symbols typically identify similar components, unless contextdictates otherwise. The illustrative embodiments described in thedetailed description, drawings, and claims are not meant to be limiting.Other embodiments may be utilized, and other changes may be made,without departing from the spirit or scope of the subject matterpresented here.

Various disclosed embodiments include illustrative dual power invertermodules, electric vehicles, and methods.

Referring now to FIGS. 1A and 1B and given by way of overview, invarious embodiments an electric vehicle 10 includes a vehicle body 12. Ahigh voltage direct current (DC) electrical battery 14 is disposedwithin the vehicle body 12. Left and right front wheels 16 (only theleft front wheel 16 is shown) and left and right rear wheels 18 (onlythe left rear wheel 18 is shown) are configured to rotate. At least onedrive unit 20 is mechanically couplable to rotate the front wheels 16 orthe rear wheels 18 (and in some embodiments one drive unit 20 may bemechanically couplable to rotate the front wheels 16 and another driveunit 20 may be mechanically couplable to rotate the rear wheels 18).Each drive unit 20 is electrically connectable to receive high voltageDC electrical power from the battery 14. Each drive unit 20 includesaxles 22A and 22B that are mechanically couplable to rotate anassociated wheel 16 or 18 and electrical motors 24A and 24B mechanicallycouplable to rotate its associated axle 22A and 22B, respectively. Aswill be explained below, each drive unit 20 also includes a dual powerinverter module 26 that is electrically connectable to receive the highvoltage DC electrical power from the battery 14. The dual power invertermodule 26 includes two inverters (not shown) configured to createthree-phase, high voltage alternating current (AC) electrical power fromthe high voltage DC electrical power and provide the three-phase, highvoltage AC electrical power to an associated electrical motor. A commoncontroller (not shown) is configured to control both of the inverters inthe dual power inverter module 26

For sake of brevity, illustrative details are set forth below by way ofnon-limiting examples in the context of a motor vehicle. However, itwill be appreciated that the vehicle 10 can be any type of vehiclewhatsoever as desired without limitation. Given by way of non-limitingexample, in various embodiments the vehicle 10 may be an electricvehicle (that is, an all-electrically driven vehicle) or a hybridvehicle. For example and given by way of non-limiting examples, invarious embodiments the vehicle 10 may include a motor vehicle driven bywheels and/or tracks, such as, without limitation, an automobile, atruck, a sport utility vehicle (SUV), a van, an all-terrain vehicle(ATV), a motorcycle, an electric bicycle, a tractor, a lawn mower suchas without limitation a riding lawn mower, a snowmobile, and the like.Given by way of further non-limiting examples, in various embodimentsthe vehicle 10 may include a marine vessel such as, without limitation,a boat, a ship, a submarine, a submersible, an autonomous underwatervehicle (AUV), and the like. Given by way of further non-limitingexamples, in various embodiments the vehicle 10 may include an aircraftsuch as, without limitation, a fixed wing aircraft, a rotary wingaircraft, and a lighter-than-air (LTA) craft.

Also for sake of brevity, illustrative details regarding the drive unit20 are set forth in the context of a motor vehicle. Because the vehicle10 is not limited to the illustrative example of a motor vehicle, itwill be appreciated that the drive unit 20 also is not limited toapplicability to a motor vehicle. To that end, in various embodimentsthe motor (or motors) of the drive unit 20 are configured to drive thevehicle 10. That is, in various embodiments the electric motor (ormotors) of the drive unit 20 may drive any drive member that drives anypropulsion device, such as without limitation a wheel or wheels, a trackor tracks, a propellor or propellors, a propulsor or propulsors, a rotoror rotors, or the like, associated with the vehicle 10.

For example, in some embodiments in a motor vehicle one drive unit 20may include one motor configured to drive one drive member such as anaxle or a chain ring that drives one wheel or track, in some otherembodiments in a motor vehicle one drive unit 20 may include one motorconfigured to drive an axle that rotates two wheels or two tracks, andin some other embodiments in a motor vehicle one drive unit 20 mayinclude one motor configured to drive an axle that rotates one wheel orone track and another motor configured to drive another axle thatrotates another wheel or another track.

Similarly, in some embodiments in a marine vessel one drive unit 20 mayinclude one motor configured to drive one propeller or propulsor, insome other embodiments in a marine vessel one drive unit 20 may includeone motor configured to drive a shaft that rotates two propellers or twopropulsors, and in some other embodiments in a marine vessel one driveunit 20 may include one motor configured to drive a shaft that rotatesone propeller or propulsor and another motor configured to drive anothershaft that rotates another propeller or propulsor.

Likewise, in some embodiments in an aircraft one drive unit 20 mayinclude one motor configured to drive one propeller or rotor, in someother embodiments in an aircraft one drive unit 20 may include one motorconfigured to drive a shaft that rotates two propellers or two rotors,and in some other embodiments in an aircraft one drive unit 20 mayinclude one motor configured to drive a shaft that rotates one propelleror rotor and another motor configured to drive another shaft thatrotates another propeller or rotor.

Now that an overview has been set forth, illustrative details will beexplained with examples that are given by way of illustration only andnot of limitation.

As mentioned above, the at least one drive unit 20 is mechanicallycouplable to rotate the front wheels 16 or the rear wheels 18 (and insome embodiments one drive unit 20 may be mechanically couplable torotate the front wheels 16 and another drive unit 20 may be mechanicallycouplable to rotate the rear wheels 18). As also mentioned above, eachdrive unit 20 includes the axles 22A and 22B that are mechanicallycouplable to rotate an associated wheel 16 or 18 and electrical motors24A and 24B that are mechanically couplable to rotate its associatedaxle 22A and 22B, respectively.

Referring additionally to FIGS. 2A-2E, in various embodiments eachelectrical motor 24A and 24B is mechanically couplable to rotate itsassociated axle 22A and 22B, respectively, via a set of gears 28A and28B, respectively. Each set of gears 28A and 28B is configured toprovide speed and torque conversions from its associated electricalmotor 24A or 24B, respectively, to its associated axle 22A or 22B,respectively, and, ultimately, an associated wheel 16 or 18.

As shown in FIG. 2D, a shaft 21A is configured to be rotated by itsassociated rotor 27 of its electrical motor 24A and a shaft 21B isconfigured to be rotated by its associated rotor 27 of its electricalmotor 24B. The shafts 21A and 21B are supported and constrained withinbearings (not shown) disposed on a frame 19. The set of gears 28A isdisposed within the frame 19 and is configured to rotatably engage theaxle 22A and the set of gears 28B is disposed within the frame 19 and isconfigured to rotatably engage the axle 22B. The electrical motor 24A isconfigured to rotatably engage the set of gears 28A and the electricalmotor 24B is configured to rotatably engage the set of gears 28B.

In various embodiments, each of the sets of gears 28A and 28B isconfigured to provide speed and torque conversions from its associatedelectrical motor 24A or 24B to its associated axle 22A or 22B and,ultimately, an associated wheel 16 or 18. For example and given by wayof illustration only and not of limitation, in various embodiments agear 28C is configured to be rotated by its associated shaft 21A or 21B.A gear 28D is mounted on a shaft (not shown for purposes of clarity) andis configured to be meshedly engaged by the gear 28C. A gear 28E also ismounted on the shaft (not shown for purposes of clarity). A gear 28F ismounted on the axle 22A or 22B and is configured to be meshedly engagedby the gear 28E. It will be appreciated that, in various embodiments,the sets of gears 28A and 28B may include any number of suitable gears(such as, without limitation, planetary gears) with gear ratios selectedas desired for a particular application to achieve desired speed andtorque conversions. It will be appreciated that gears for use inelectric vehicles are well known in the art. Therefore, furtherdescription of their construction and operation are not necessary for anunderstanding of disclosed subject matter.

In some embodiments, the axles 22A and 22B may be fixedly couplable totheir associated wheels 16 or 18. For example and without limitation, insome such embodiments the front wheels 16 may be fixedly couplable totheir associated axles 22A and 22B. It will be appreciated that suchfixed coupling may help contribute to reducing mechanical complexity andmay help contribute to enabling the front wheels 16 to remain steerable(such as when the vehicle 10 is being towed with the front wheels 16 andthe rear wheels 18 engaged on a surface of a road (that is, flattowing)).

In some other embodiments, the axles 22A and 22B may be removablycouplable to their associated wheels 16 or 18. For example and withoutlimitation, in some such embodiments the rear wheels 18 may be removablycouplable to their associated axles 22A and 22B. It will be appreciatedthat such removable coupling of the rear wheels 18 may help contributeto avoiding generation of braking torque and/or uncontrolled electricalgeneration during towing.

It will be appreciated that each drive unit 20 drives either left andright front wheels 16 or left and right rear wheels 18. Therefore, bothof the electrical motors 24A and 24B of a given drive unit 20 mayexperience a same or similar range of speed and torque demands. Toservice such ranges of speed and torque demands, in various embodimentsboth of the electrical motors 24A and 24B of a given drive unit 20 mayhave the same voltage and current ratings. For example, in variousembodiments (such as in high voltage systems), a voltage rating may bein a range from around 300 Vrms to around 600 Vrms line-to-line and acurrent rating may be in a range from around 300 Arms to around 900Arms. Given by way of non-limiting example by way of illustration only,an illustrative voltage rating may be 312 Vrms and an illustrativecurrent rating may be 550 Arms (based on a 400 VDC system). However, itwill be appreciated that the electrical motors 24A and 24B may have anyvoltage ratings and any current ratings as desired for a particularapplication.

In various embodiments, the electrical motors 24A and 24B may be anysuitable type of electrical motor as desired. For example, in someembodiments the electrical motors 24A and 24B may include synchronouselectrical motors. In some such embodiments, the synchronous electricalmotors may include without limitation permanent magnet electrical motorsor the like. In some other embodiments the electrical motors 24A and 24Bmay include without limitation an asynchronous motor (or inductionmotor)—like a polyphase AC induction motor or the like.

As mentioned above, in various embodiments each drive unit 20 driveseither left and right front wheels 16 or left and right rear wheels 18and, therefore, both of the electrical motors 24A and 24B of a givendrive unit 20 may experience a same or similar range of speed and torquedemands. Therefore, in various embodiments both inverters of a givendrive unit 20 may have the same voltage output ratings and the samecurrent output ratings. Given by way of illustration only and not oflimitation, in various embodiments both inverters of a given drive unit20 may have a voltage output rating of 312 Vrms and a current outputrating of 550 Arms (based on 400 VDC input). However, it will beappreciated that the inverters of a given drive unit 20 may have anyvoltage output ratings and any current output ratings as desired for aparticular application.

It will be appreciated that, in various embodiments, the dual powerinverter module 26 may be physically associated with the frame 19 in anysuitable manner as desired for a particular application. For example andwithout limitation, in some embodiments and as shown in FIGS. 2A-2C thedual power inverter module 26 may be a module within a sealed containerand physically disposed on the frame 19 external to the frame. Asanother example and as shown in FIG. 2E without limitation, in someother embodiments the dual power inverter module 26 may be integratablymountable with the frame 19. In some such embodiments a housing 29 hasan open face (not shown) defined therein. Inverter circuitry (discussedbelow) is disposed in the housing 29. In such embodiments, the open faceof the housing 29 is mated to an opening (not shown) in the frame 19.Such other embodiments are discussed in commonly-owned U.S. patentapplication Ser. No. 17/244,288 filed Apr. 29, 2021 entitled “INVERTERMODULE INTEGRATABLY MOUNTABLE WITH DRIVE UNIT OF VEHICLE” assigned toand filed by Applicant, the entire contents of which are herebyincorporated by reference.

Referring additionally to FIGS. 3A and 3B, in various embodiments a dualpower inverter module (DPIM) 26 is provided. As mentioned above, invarious embodiments the DPIM 26 includes two inverters 30A and 30Bconfigured to create three-phase, high voltage AC electrical power fromthe high voltage DC electrical power and provide the three-phase, highvoltage AC electrical power to an associated electrical motor 24A or 24Band a common controller 32 configured to control both of the inverters30A and 30B.

In various embodiments, a DC link capacitor 34 is electricallyconnectable to a source of high voltage DC electrical power, such as thebattery 14. In some embodiments, an electrical connection to the battery14 may include an electrical connection 36. Suitable electrical cables38 may be electrically connected to the electrical connection 36 and maybe electrically connectable to the electrical battery 14.

In various embodiments, a power inverter 30A is electrically connectableto the DC link capacitor 34 and is configured to convert high voltage DCelectrical power to three phase high voltage AC electrical power. Thepower inverter 30A is further configured to supply the three phase highvoltage AC electrical power to an electric motor 24A, such as a rightmotor or a left motor. A power inverter 30B is electrically connectableto the DC link capacitor 34 and configured to convert high voltage DCelectrical power to three phase high voltage AC electrical power. Thepower inverter 30B is further configured to supply the three phase highvoltage AC electrical power to an electric motor 24B, such as the otherof the left motor or right motor.

In various embodiments the common controller 32 is electricallyconnectable to the power inverter 30A and the power inverter 30B. Thecommon controller 32 is configured to control the power inverter 30A andthe power inverter 30B. The common controller 32 may be any suitablecomputer processor-based controller as desired. Given by way of exampleonly and not of limitation, in various embodiments the common controller32 may include a computer processing unit (CPU), a general purposeprocessor, a digital signal processor, a field programmable gate array,or the like, and/or any combination thereof. While controllers are wellknown and further description of their construction and operation arenot necessary for an understanding of disclosed subject matter, furtherdetails regarding the common controller 32 will be set forth belowregarding additional functions.

In various embodiments, the common controller 32 is electricallyconnectable to receive low voltage DC electrical power, such as 12 VDC.The common controller 32 also is electrically connectable to receivevehicle status signals and vehicle fault indication signals.Illustrative responses to various vehicle faults and to loss of 12 VDCwill be discussed further below.

In various embodiments, the power inverter 30A and the power inverter30B each include a bank 40 of three-terminal power semiconductor devices42 and a bank 44 of the three-terminal power semiconductor devices 42.

In some embodiments, the three-terminal power semiconductor devices 42may include insulated gate bipolar transistors (IGBTs). In some suchembodiments, the IGBTs may include silicon (Si) IGBTs. In someembodiments, the three-terminal power semiconductor devices 42 mayinclude metal-oxide-semiconductor field effect transistors (MOSFETs). Insome such embodiments, the MOSFETs may include silicon carbide (SiC)MOSFETs. However, it will be appreciated that the three-terminal powersemiconductor devices 42 may also include power semiconductor devices 42that include at least three terminals and may include additionalterminals—such as, for example and without limitation, Kelvin sourceterminal, Kelvin emitter terminal, current sense terminal, and/ortemperature sense terminal.

It will be appreciated that SiC MOSFETS may offer advantages over SiIGBTs at low phase currents and that SiC MOSFETS have lower conductiondrop compared to IGBTs below 700 Apk. However, it will be appreciatedthat this value may change depending upon size of the inverter. As such,it will be appreciated that SiC MOSFETS may offer up to around 3-5%efficiency gains over a typical drive cycle, as compared to Si IGBTs.

In some all-wheel drive (AWD) electric vehicles 10, the front wheels 16function as the only drive wheels until additional torque and/or powerbeyond a predetermined amount is entailed. In such electric vehicles 10,the rear wheels are only driven by their associated drive unit 20 whentorque and/or power beyond the predetermined amount is to be delivered.In some such AWD electric vehicles 10, to take advantage of efficienciesof SiC MOSFETS over Si IGBTs the drive unit 20 that drives the frontwheels 16 may include inverters 40 that include SiC MOSFETS and thedrive unit 20 that drives the rear wheels 18 may include inverters 40that include Si IGBTs. However, it will be appreciated that any of thedrive units 20 may include inverters 40 that include either SiC MOSFETSor Si IGBTs as desired.

In various embodiments the power inverter 30A includes a gate drivecircuit 46A configured to drive gate terminals 48 of the banks 40 and 44of three-terminal power semiconductor devices 42 of the power inverter30A. Similarly, the power inverter 30B includes a gate drive circuit 46Bconfigured to drive gate terminals 48 of the banks 40 and 44 ofthree-terminal power semiconductor devices 42 of the power inverter 30B.In various embodiments the controller 32 is configured to, among otherfunctions, generate low-power turn on and turn off signals 66A and 66Band provide the turn on and turn off signals 66A and 66B to the gatedrive circuits 46A and 46B, respectively. The low-power turn on and turnoff signals 66A and 66B may be on the order of a few milliamperes ofelectrical current and logic level voltages such as 3.3 or 5V.

In various embodiments the gate drive circuits 46A and 46B includesuitable power amplifiers that amplify the low-power turn on and turnoff signals 66A and 66B and generate high-power turn on and turn offsignals 66A′ and 66B′. To drive the gate terminals 48, the high-powerturn on and turn off signals 66A′ and 66B′ may be on the order ofseveral hundreds of milliamperes of electrical current or on the orderof amperes of electrical current, with voltages in the range of 15-20V,as desired for a particular application. The high-power turn on and turnoff signals 66A′ and 66B′ are, in turn, electrically coupled to driveassociated gate terminals 48. Gate drive circuits are well known andfurther description of their construction and operation are notnecessary for an understanding of disclosed subject matter.

In view of the illustrative details provided above by way ofnon-limiting examples, it will be appreciated that, in variousembodiments, provision of one controller 32 for two inverters 30A and30B can provide for use of: (i) a single interface for vehicle statussignals and vehicle fault indication signals; (ii) a single DC linkcapacitor 34; (iii) a single common controller 32; and (iv) a singleinterface for low voltage DC electrical power (such as 12 VDC).

In view of the illustrative details provided above by way ofnon-limiting examples, it will be appreciated that, in variousembodiments, integrating the mounting of the DPIM 26 with the drive unit20 can provide for integration of coolant interfaces. For example, invarious embodiments water cooling provided for the inverters 30A and 30Bcan be provided to stator windings of the electrical motors 24A and 24B.

As discussed above, in various embodiments a single motor 24A or 24Bdrives a single wheel, such as one front wheel 16 or one rear wheel 18.It will be appreciated that each wheel can operate at a unique speed andtorque. Given by way of non-limiting examples, going around a curve orloss of traction can create different wheel speeds and traction controlor torque vectoring can result in different wheel torques. As alsodiscussed above, in various embodiments the dual power inverter module26 combines two inverters 30A and 30B into one module 26 and, as such,shares common components, such as the DC link capacitor 34.

To that end, various embodiments include only one DC link capacitor 34that is electrically connectable to provide high voltage DC electricalpower to both inverters 30A and 30B of the DPIM 26. It will beappreciated that it may be desirable to reduce and possibly minimizesize of the DC link capacitor 34. As explained below, variousembodiments can help contribute to reducing stress on the DC linkcapacitor 34 (that may have a reduced size) and ripple current on the DChigh voltage bus (that may include the electrical cables 38) due togeneration of high-frequency current harmonics from the inverters 30Aand 30B.

In various embodiments, the inverters 30A and 30B use pulse widthmodulation (PWM) to create a variable amplitude and frequency voltagesource to drive the electric motors 24A and 24B. Different PWM methods(such as, for example, continuous PWM and discontinuous PWM) can beemployed as desired for a particular situation. Each of the PWM methodscreates its own unique harmonic spectrum of ripple current that may bereflected on the DC bus.

For example, in continuous PWM each phase is switching continuously(that is, in various embodiments all of the three-terminal powersemiconductor devices 42 in both of the inverters 30A and 30B areswitching continuously). As a result, continuous PWM can result in anot-insignificant amount of switching losses in the inverters 30A and30B. In continuous PWM, the second harmonic of the switching frequencyis the dominant harmonic frequency in the ripple current. Continuous PWM(such as space vector modulation) can be used in situations such as whenit is desired to minimize harmonic content and ripple on AC output andDC input currents, as well as minimize acoustic noise. For example, somevehicles might use continuous PWM at high torque to minimize acousticnoise.

As another example, in discontinuous PWM each phase is not switchingcontinuously (that is, in various embodiments all of the three-terminalpower semiconductor devices 42 in both of the inverters 30A and 30B arenot switching continuously). In such embodiments, only two of the threephases are switching at any one time, and the remaining third phase haseither the upper or lower switch turned on continuously, thereby helpingto contribute to increasing inverter efficiency and helping tocontribute to reducing losses during discontinuous PWM. It will beappreciated that use of discontinuous PWM may have other non-beneficialeffects, such as increased acoustic noise or harmonic content in the ACoutput or DC input currents. In discontinuous PWM each phase has two 60degree segments where the switches are held either low or high, and isnot switching for a total of 120 degrees over a fundamental period. Thatis, in discontinuous PWM each phase is not switching one-third of thetime. This results in significantly lower switching losses and higherefficiency. It will be appreciated that, while discontinuous PWM entailslower switching losses than those entailed in continuous PWM,discontinuous PWM may entail higher acoustic noise than that associatedwith continuous PWM and harmonics may be placed onto the motors 24A and24B as well as the DC link capacitor 34. In discontinuous PWM, the firstharmonic of the switching frequency is the dominant harmonic frequency.Discontinuous PWM can be used in situations when the highest efficiencyand lowest losses are desired, and acoustic noise is not problematic. Asan example, some vehicles might have thermal problems at high torqueand, as a result, use discontinuous PWM to reduce losses under thoseconditions.

In various embodiments and referring additionally to FIG. 4A, the DClink capacitor 34 is used to decouple effects of inductance L_(cable)from the DC voltage source (that is, the electrical battery 14) to theinverters 30A and 30B. Referring additionally to FIGS. 4B and 4C, the DClink capacitor 34 provides a low impedance path for ripple currents 50that are generated by the inverters 30A and 30B and might otherwise flowback onto the DC high voltage bus. The ripple currents 50 are a factorin sizing the DC link capacitor 34 and, as a result, reducing the ripplecurrents 50 can help contribute to reducing size of the DC linkcapacitor 34 (and stress on the DC link capacitor 34). The ripplecurrents 50 are a result of the AC load current flowing into the motors24A and 24B and pulse width modulation (PWM) of the inverters 30A and30B. As shown in FIGS. 4B and 4C and given by way of illustration onlyand not of limitation, with a motor current of 550 Arms, a modulationindex of 0.48, a power factor of 1, a switching frequency of 10 KHz, anda fundamental frequency of 250 Hz, without cancellation the ripplecurrents 50 can have an amplitude of around 712 Arms.

Referring additionally to FIG. 4D, in various embodiments a method 52 isprovided for synchronizing pulse width modulation clocks. It will beappreciated that, in various embodiments, synchronizing pulse widthmodulation clocks can help contribute to cancelling the ripple currents50. The method 52 begins at a block 53. At a block 54 a pulse widthmodulation method of a first power inverter and a pulse width modulationmethod of a second power inverter are identified. At a block 56, aswitching frequency of the first power inverter and a switchingfrequency of the second power inverter are identified and compared. At ablock 58, an optimized phase shift between the first power inverter andthe second power inverter is determined responsive to the pulse widthmodulation method of the first power inverter and the pulse widthmodulation method of the second power inverter and the switchingfrequency of the first power inverter and the switching frequency of thesecond power inverter. At a block 60 the optimized phase shift issynchronized between the first power inverter and the second powerinverter.

The method 52 ends at a block 61.

As shown in FIGS. 4E and 4F and given by way of illustration only andnot of limitation, with a motor current of 550 Arms, a modulation indexof 0.48, a power factor of 1, a switching frequency of 10 KHz, and afundamental frequency of 250 Hz, with cancellation as described hereinthe ripple currents 50 can be reduced to have an amplitude of around 147Arms.

With the above overview in mind, in various embodiments and as shown inFIG. 3A the common controller 32 includes a processor 64A and aprocessor 64B. In some embodiments the processors 64A and 64B may beseparate processors. However, it will be appreciated that in some otherembodiments (that use two PWM generators) the functions of theprocessors 64A and 64B may be combined into a single processor (e.g.,using multitasking, multithreading, time slicing, and the like) asdesired for a particular application. Regardless of the processors 64Aand 64B being separate or combined into a single processor, it will beappreciated that the processor 64A functions as a Master (or in the caseof a single processor, the functions of processor 64A function as Masterprocesses) and the processor 64B functions as a Slave (or in the case ofa single processor, the functions of processor 64B function as Slaveprocesses).

The processor 64A is operably coupled to computer-readable media 65A,such as any suitable computer memory, configured to storecomputer-executable instructions configured to cause the processor 64Ato perform functions described below. The processor 64B is operablycoupled to computer-readable media 65B, such as any suitable computermemory, configured to store computer-executable instructions configuredto cause the processor 64B to perform functions described below. Theprocessor 64A is configured to generate a first clock signal (e.g.,using a crystal) for controlling generation of the turn on and turn offsignal 66A for driving the power inverter 30A and a second clock signal.The second clock signal is provided to the processor 64B for controllinggeneration of the turn on and turn off signal 66B for driving the powerinverter 30B.

The processor 64A selects a PWM method for the power inverter 30A andthe processor 64B selects a PWM method for the power inverter 30B. Theprocessor 64B (that is, the Slave) informs the processor 64A (that is,the Master) of its PWM method (except for cases where switching of PWMmethods is not employed). Factors for selection of continuous PWM anddiscontinuous PWM have been discussed above.

The processor 64A selects a switching frequency for the power inverter30A and the processor 64B selects a switching frequency for the powerinverter 30B. The frequencies are even multiples of each other, and areselected from predetermined values. Given by way of illustration onlyand not of limitation, in various embodiments the switching frequenciesmay be 2.5 KHz and 10 KHz, thereby resulting in an even multiple offour. However, it will be appreciated that other frequencies may beselected as desired (that result in even multiples). In variousembodiments the processor 64A (that is, the Master) puts out a referencethat is at the lowest selectable frequency, with the desired phase shiftas a function of the PWM modes.

The processor 64A is configured to determine an optimized phase shiftbetween the power inverter 30A and the power inverter 30B responsive tothe PWM method of the power inverter 30A and the PWM method of the powerinverter 30B and the switching frequency of the power inverter 30A andthe switching frequency of the power inverter 30B. For example, in somesuch embodiments and referring additionally to FIG. 4G, the processor64A may access a look-up-table 68 that is populated with cells thatinclude values of optimized phase shift arranged according to rows 70 ofPWM method and columns 72 of PWM method. It will be appreciated that, insome embodiments, the PWM method of the power inverter 30A and the PWMmethod of the power inverter 30B may be the same pulse width modulationmethod. It will also be appreciated that, in some other embodiments, thePWM method of the power inverter 30A and the PWM method of the powerinverter 30B may be different PWM methods.

As shown in FIG. 4G, when both of the power inverters 30A and 30B usecontinuous PWM, the phase shift is set to 90 degrees. When both of thepower inverters 30 A and 30B use discontinuous PWM, the phase shift isset to 180 degrees. In the event of different PWM methods, the phase isset to 90 degrees.

In some other such embodiments, the processor 64A may execute analgorithm for determining an optimized phase shift between the powerinverter 30A and the power inverter 30B responsive to the PWM method ofthe power inverter 30A and the PWM method of the power inverter 30B. Forexample, the algorithm may include if-then statements, such as:

if both PWM methods are continuous PWM, then the optimized phase shiftis 90 degrees;

if both PWM methods are discontinuous PWM, then the optimized phaseshift is 180 degrees; and

if one PWM method is continuous PWM and another PWM method isdiscontinuous PWM, then the optimized phase shift is 90 degrees.

The processor 64A is also configured to synchronize the optimized phaseshift between the power inverter 30A and the power inverter 30B. Asmentioned above, the processor 64B is configured to receive the secondclock signal and to drive the power inverter 30B.

In various embodiments, the processor 64A is further configured to shiftthe second clock signal from the first clock signal by the determinedoptimized phase shift.

In various embodiments, the processor 64A is further configured toidentify a dominant harmonic frequency among harmonic frequencies of thePWM method of the power inverter 30A and the PWM method of the powerinverter 30B and to determine the optimized phase shift between thepower inverter 30A and the power inverter 30B responsive to the dominantharmonic frequency among the harmonic frequencies of the PWM method ofthe power inverter 30A and the PWM method of the power inverter 30B. Itwill be appreciated that determining the optimized phase shift betweenthe power inverter 30A and the power inverter 30B responsive to thedominant harmonic frequency among the harmonic frequencies of the PWMmethod of the power inverter 30A and the PWM method of the powerinverter 30B can help contribute to cancelling dominant high frequencycomponents of the ripple currents 50.

In some such embodiments, the dominant harmonic frequency may include asecond harmonic frequency (harmonic of the switching frequency). Forexample, in such embodiments the PWM method may include continuous PWM.In such embodiments, the optimized phase shift is 90 degrees. It will beappreciated that a phase shift of 90 degrees shifts the dominantharmonic (second harmonic frequency) by 180 degrees, thereby resultingin cancellation of the dominant harmonic component of the ripple current50.

In some other such embodiments, the dominant harmonic frequency mayinclude a first harmonic frequency. For example, in such embodiments thePWM method may include discontinuous PWM. In such embodiments, theoptimized phase shift is 180 degrees. It will be appreciated that aphase shift of 180 degrees shifts the dominant harmonic (first harmonicfrequency) by 180 degrees, thereby resulting in cancellation of thedominant harmonic component of the ripple current 50.

It will be appreciated that actual DC bus harmonics may reside in sideband groups surrounding the switching frequency. The separation of theseharmonics from the switching frequency harmonic is a function of themotor fundamental frequency.

In various embodiments the processor 64A is configured to identify andcompare a switching frequency of the power inverter 30A and a switchingfrequency of the power inverter 30B. As discussed above, only twofrequencies that are even multiples of each other are used.

For example, in some embodiments it may be desirable to change switchingfrequency. For example, in some embodiments switching frequency may be10 KHz. In such embodiments, at low motor speed (for example, below 500RPM) it may be desirable to reduce switching frequency to 2.5 KHz toprotect the switches 42 in the inverters 30A and 30B, thereby helping toreduce stresses in the inverters 30A and 30B. Maintaining even multiplerelation between the switching frequencies allows for alignment ofharmonics and increased opportunity for cancellation of dominantharmonics.

Electric vehicles in which each wheel is independently driven by its ownassociated electrical motor via its own axle does not have anymechanical coupling between the wheels. In such vehicles, if oneinverter shuts down due to a fault and the other inverter does not reactappropriately, then a torque difference might exist between the twowheels. Such a resultant torque difference might have negative impact oncontrollability of the vehicle.

To help avoid such a torque difference and referring additionally toFIGS. 5A-5G, in various embodiments a fault that is associated witheither the power inverter 30A or the power inverter 30B (or circuitrydescribed below that is associated with both the inverters 30A and 30B)results in application of a same fault action (described below) to boththe inverters 30A and 30B. In such embodiments, application of the samefault action to both the inverters 30A and 30B puts both the inverters30A and 30B in a “safe state” and helps contribute to applying anequalized torque to both of the wheels associated with the drive unit 20that includes the inverters 30A and 30B. By applying the same faultaction to both the inverters 30A and 30B and equalizing torque to bothof the wheels associated with the drive unit 20 that includes theinverters 30A and 30B, various embodiments are able to help contributeto reducing the possibility of generation of torque difference thatmight have negative impact on controllability of the vehicle.

As discussed above, the processor 64A is operably coupled tocomputer-readable media 65A, such as any suitable computer memory,configured to store computer-executable instructions configured to causethe processor 64A to perform functions described below. As alsodiscussed above, the processor 64B is operably coupled tocomputer-readable media 65B, such as any suitable computer memory,configured to store computer-executable instructions configured to causethe processor 64B to perform functions described below. In variousembodiments and as will be described below, the computer-executableinstructions are configured to cause its associated processor 64A and64B to apply a same fault action to the power inverter 30A and the powerinverter 30B, respectively, for applying equalized torque to each wheel16 or 18 operatively coupled to the drive unit 20 responsive to a faultassociated with the power inverter 30A or the power inverter 30B

In various embodiments and as shown in FIG. 5A, various faultsassociated with the inverters 30A and 30B are monitored by theprocessors 64A and 64B for the inverters 30A and 30B, respectively. Forsuch faults, in various embodiments the same fault response is appliedby the processors 64A and 64B to the three-terminal power semiconductordevices 42 (FIG. 3A) of both of the inverters 30A and 30B. In variousembodiments, such faults associated with the inverters 30A and 30B andmonitored by the processors 64A and 64B, respectively, may include,without limitation, overcurrent, overvoltage, undervoltage, overtemperature, overspeed, and the like. In various embodiments, signalsindicative of such faults may be provided to the controller 32 via adata link 74 that may include any suitable data communication connectionor network as desired, such as without limitation a wide area network(WAN), a local area network (LAN), a controller area network (CAN), apeer-to-peer network, a data bus, or the like and provided to theprocessors 64A and 64B. In various embodiments, signals indicative ofvehicle status, such as motor speed and voltage of the battery 14, arealso provided to the controller 32 via the data link 74.

In various embodiments and as also shown in FIG. 5A, the controller 32includes a communications link 82 between the processors 64A and 64B. Itwill be appreciated that the communications link 82 can enable theprocessor 64A or the processor 64B to communicate to the other processor64B or 64A, respectively, that a fault monitored by the processor 64A orthe processor 64B has been detected, that a fault action is to be taken,and what fault action is to be taken. The communications link 82 mayinclude any suitable data link or data bus as desired.

In various embodiments, the fault action for a fault monitored by theprocessors 64A and 64B for the inverters 30A and 30B, respectively, mayinclude an action such as opening all of the three-terminalsemiconductor devices 42 of the inverters 30A and 30B and/or shortingthe three-terminal semiconductor devices 42 of either the bank 40 or thebank 44 of the inverters 30A and 30B. As will be explained below, invarious embodiments the fault action applied to both of the inverters30A and 30B for a fault monitored by the processors 64A and 64B dependson speed of the motors. As will also be explained below, the faultaction applied to both of the inverters 30A and 30B for a fault that isnot monitored by the processors 64A and 64B does not depend on speed ofthe motors.

In various embodiments and as mentioned above, in various embodimentsthe fault action for a fault monitored by the processors 64A and 64B forthe inverters 30A and 30B, respectively, may include an action such asopening all of the three-terminal semiconductor devices 42 of theinverters 30A and 30B and/or shorting the three-terminal semiconductordevices 42 of either the bank 40 or the bank 44 of the inverters 30A and30B and may depend on speed of the motors. For such faults that aremonitored by the processors 64A and 64B, it will be appreciated that thefault action applied to both of the inverters 30A and 30B simultaneouslycan help contribute to reducing braking torque and reducing regenerativeelectrical current to the electrical battery 14. Because the processors64A and 64B are operatively coupled to various data communicationconnections or networks to receive data regarding speed of the motors,the processors 64A and 64B suitably are configured to determine the samefault action to be applied based on speed of the motors. In variousembodiments, the processor 64A selects the appropriate speed-dependentfault action for its associated electrical motor 24A and the processor64B selects the appropriate speed-dependent fault action for itsassociated electrical motor 24B. Fault actions for other faults—that arenot monitored by the processors 64A and 64B—do not depend on speed ofthe motors and are discussed further below.

As shown in FIG. 5B, in various embodiments the same fault action to beapplied the inverters 30A and 30B may be based on speed of the motors.In such embodiments the same fault action may include opening all of thethree-terminal semiconductor devices 42 of the inverters 30A and 30Bbelow a threshold speed v_(th) of the motor and shorting thethree-terminal semiconductor devices 42 of either the bank 40 or thebank 44 of the inverters 30A and 30B above the threshold speed v_(th).

As shown in FIG. 5B, a graph 76 plots speed of the motor versus torquefor various conditions of the three-terminal semiconductor devices 42 ofthe inverters 30A and 30B. A curve 78 shows torque that results fromopening all of the three-terminal semiconductor devices 42 of theinverters 30A and 30B. Below the threshold speed v_(th) torque issubstantially insignificant and above the threshold speed v_(th) brakingtorque becomes increasingly significant with increased speed of themotors. It will also be appreciated that, in such instances, backelectromotive force (back EMF) increases with increasing speed of themotors which can, in some instances, result in the electrical motors 24Aand 24B possibly operating as uncontrolled generators that can generateback EMF and apply unwanted regenerated electrical current to the DClink capacitor 34 and the electrical battery 14.

As also shown in FIG. 5B, a curve 80 shows torque that results from athree-phase short of the three-terminal semiconductor devices 42 ofeither the bank 40 or the bank 44 of three-terminal semiconductordevices 42. As speed of the motors increases from zero, braking torquerapidly increases and reaches a maximum value of braking torque. Asspeed of the motors continues to increase, braking torque decreases andapproaches an asymptotic minimized value before the speed of the motorsreaches the threshold speed v_(th).

Thus, in various embodiments in which the fault is monitored by theprocessors 64A and 64B for the inverters 30A and 30B, the fault actionsuitably includes a speed-dependent fault action that can helpcontribute to simultaneously minimize braking torque and unwantedregenerative electrical current to the DC link capacitor 34 and theelectrical battery 14. In such embodiments, the fault action suitablyincludes opening all of the three-terminal power semiconductor devices42 of both of the inverters 30A and 30B when the speed of the motors isless than the threshold speed v_(th) and shorting the three-terminalpower semiconductor devices 42 of one bank of the three-terminal powersemiconductor devices 42 (that is, either the bank 40 or the bank 44) ofthe inverters 30A and 30B when the speed of the motors is greater thanthe threshold speed v_(th).

In various embodiments, fault actions based on the curve 78 and thegraph 80 may be implemented using back EMF and voltage of the battery 14(as opposed to taking fault action directly in response to reportedmotor speed). For example, in various embodiments motor back EMF iscomputed and is compared to voltage of the battery. In such embodiments,when back EMF is less than battery voltage (by a design safety marginselected as desired), then a speed-dependent fault action includesopening all of the three-terminal power semiconductor devices 42 of bothof the inverters 30A and 30B. When back EMF exceeds a predeterminedpercentage of battery voltage, then a speed-dependent fault actionincludes shorting the three-terminal power semiconductor devices 42 ofone bank of the three-terminal power semiconductor devices 42 (that is,either the bank 40 or the bank 44) of the inverters 30A and 30B. Ifdesired, use of an amount of hysteresis can prevent “chattering”back-and-forth between different fault actions.

As shown in FIG. 5A, the processor 64A is associated with the powerinverter 30A and the processor 64B is associated with the power inverter30B. The memory 65A (that is, computer-readable media) and the memory65B (again, computer-readable media) each are configured to storecomputer-executable instructions configured to cause its associatedprocessor 64A and 64B, respectively, to apply the same fault action tothe power inverter 30A and the power inverter 30B for applying equalizedtorque to each wheel 16 or 18 operatively coupled to the drive unit 20responsive to a fault associated with the power inverter 30A or thepower inverter 30B.

As also shown in FIG. 5A, in various embodiments signals that areindicative of parameters such as vehicle speed, faults such as thosedescribed above, and the like are supplied to the controller 32 via thedata link 74 and are provided to the processors 64A and 64B. In suchembodiments the computer-executable instructions are further configuredto cause its associated processor 64A or 64B to monitor for the fault.

Low-voltage DC electrical power (such as 12V) is provided to thecontroller 32 for powering components as desired. The controller 32, inturn, provides 12V DC electrical power to the gate drive circuits 46Aand 46B.

As shown in FIG. 5A, the processor 64A is operatively coupled to providea control signal 86 to drives 46A1 for the gates 48 of the bank 40(sometimes referred to as an “upper bank”) and a control signal 88 todrives 46A2 for the gates 48 of the bank 44 (sometimes referred to as a“lower bank”). Similarly, the processor 64B is operatively coupled toprovide a control signal 90 to drives 46B1 for the gates 48 of the bank40 (sometimes referred to as an “upper bank”) and a control signal 92 todrives 46B2 for the gates 48 of the bank 44 (sometimes referred to as a“lower bank”). In various embodiments the drives 46A1, 46A2, 46B1, and46B2 are suitable power amplifiers that amplify the low-power controlsignals 86, 88, 90, and 92 and generate high-power, fault action signals86′, 88′, 90′, and 92′ that are, in turn provided to their associatedgate terminals 48.

As shown in FIG. 5C, in various embodiments additional circuitry isentailed in providing the control signals 86, 88, 90, and 92 to theirrespective drives 46A1, 46A2, 46B1, and 46B2. Each processor 64A and 64Bis operatively coupled to receive the fault indication signal asdiscussed above, and the processors 64A and 64B are operatively coupledwith each other via the communications link 82. The processor 64A isoperatively coupled to provide the control signals 86 and 88 to buffers94 and 96, respectively, and the processor 64B is operatively coupled toprovide the control signals 90 and 92 to buffers 98 and 100,respectively. The buffers 94, 96, 98, and 100 are any suitable buffer,such as without limitation an octal buffer or the like.

The buffer 94 is operatively coupled to the drives 46A1, the buffer 96is operatively coupled to the drives 46A2, the buffer 98 is operativelycoupled to the drives 46B1, and the buffer 100 is operatively coupled tothe drives 46B2. When a monitored fault indication signal for anassociated inverter 30A or 30B is received by either the processor 64Aor the processor 64B, the processor that receives the monitored faultindication signal communicates existence of the monitored fault via thecommunications link 82. Fault actions are taken as follows.

When the processor 64A receives a fault indication signal, the processor64A communicates to the processor 64B via the communications link 82that a fault monitored by the processor 64A has been detected, that afault action is to be taken by the processor 64B, and (as discussedbelow) what fault action is to be taken by the processor 64B.Conversely, when the processor 64B receives a fault indication signal,the processor 64B communicates to the processor 64A via thecommunications link 82 that a fault monitored by the processor 64B hasbeen detected, that a fault action is to be taken by the processor 64A,and (as discussed below) what fault action is to be taken by theprocessor 64A. It will also be appreciated that in various embodimentsthe processor that receives the fault indication signal also performsthe fault action (that it asks the other processor to take as well).

When speed of the motors is less than the threshold speed v_(th) (orback EMF is less than voltage of the battery 14 by at least a designsafety margin) and a fault has been detected, the processors 64A and 64Bgenerate the control signals 86, 88, 90, and 92 that are configured toturn off all the gate terminals 48 of the inverters 30A and 30B and, asa result, cause all of the three-terminal power semiconductor devices 42of the inverters 30A and 30B to open. The control signals 86, 88, 90,and 92 are provided to the buffers 94, 96, 98, and 100, respectively,and are, in turn, provided to the drives 46A1, 46A2, 46B1, and 46B2which provide the fault action signals 86′, 88′, 90′, and 92′ to all thegate terminals 48 of the inverters 30A and 30B. As shown in FIG. 5D, allof the three-terminal power semiconductor devices 42 in the banks 40 and44 of the inverters 30A and 30B are caused to open.

When speed of the motors is greater than the threshold speed v_(th) (orback EMF exceeds a predetermined percentage of battery voltage) and afault has been detected, the processors 64A and 64B generate the controlsignals 86, 88, 90, and 92 that are configured to turn off the gateterminals 48 of the three-terminal power semiconductor devices 42 in oneof the banks 40 or 44 of the inverters 30A and 30B and turn on the gateterminals 48 of the three-terminal power semiconductor devices 42 in theother of the banks 44 or 40 of the inverters 30A and 30B. As a result,the three-terminal power semiconductor devices 42 of one of the banks 40or 44 of both of the inverters 30A and 30B are caused to open and thethree-terminal power semiconductor devices 42 of the other of the banks44 or 40 of both of the inverters 30A and 30B are caused to short.

It will be appreciated that the three-terminal power semiconductordevices 42 of either of the banks 40 or 44 of both of the inverters 30Aand 30B may be caused to open or short as desired. It will also beappreciated that three-terminal power semiconductor devices 42 that havefaulted will not be caused to open or short (because they have faulted).In some embodiments and as shown in FIG. 5E, the three-terminal powersemiconductor devices 42 of the bank 40 of both of the inverters 30A and30B are caused to open and the three-terminal power semiconductordevices 42 of the bank 44 of both of the inverters 30A and 30B arecaused to short. In such embodiments, the processors 64A and 64Bgenerate the control signals 86 and 90 that are configured to turn offall the gate terminals 48 in the bank 40 of the inverters 30A and 30Band, as a result, cause all of the three-terminal power semiconductordevices 42 in the bank 40 of the inverters 30A and 30B to open. Theprocessors 64A and 64B also generate the control signals 88 and 92 thatare configured to turn on all the gate terminals 48 in the bank 44 ofthe inverters 30A and 30B and, as a result, cause all of thethree-terminal power semiconductor devices 42 in the bank 44 of theinverters 30A and 30B to short. The control signals 86, 88, 90, and 92are provided to the buffers 94, 96, 98, and 100, respectively, and are,in turn, provided to the drives 46A1, 46A2, 46B1, and 46B2 which providethe fault action signals 86′, 88′, 90′, and 92′ to all the gateterminals 48 of the inverters 30A and 30B.

In some other embodiments and as shown in FIG. 5F, the three-terminalpower semiconductor devices 42 of the bank 44 of both of the inverters30A and 30B are caused to open and the three-terminal powersemiconductor devices 42 of the bank 40 of both of the inverters 30A and30B are caused to short. In such embodiments, the processors 64A and 64Bgenerate the control signals 86 and 90 that are configured to turn offall the gate terminals 48 in the banks 44 of the inverters 30A and 30Band, as a result, cause all of the three-terminal power semiconductordevices 42 in the bank 44 of the inverters 30A and 30B to open. Theprocessors 64A and 64B also generate the control signals 88 and 92 thatare configured to turn on all the gate terminals 48 in the bank 40 ofthe inverters 30A and 30B and, as a result, cause all of thethree-terminal power semiconductor devices 42 in the bank 40 of theinverters 30A and 30B to short. The control signals 86, 88, 90, and 92are provided to the buffers 94, 96, 98, and 100, respectively, and are,in turn, provided to the drives 46A1, 46A2, 46B1, and 46B2 which providethe fault action signals 86′, 88′, 90′, and 92′ to all the gateterminals 48 of the inverters 30A and 30B.

In various embodiments and as also shown in FIGS. 5A and 5C, variousfaults associated with the inverters 30A and 30B are not monitored bythe processors 64A and 64B for the inverters 30A and 30B,respectively—because such faults are faults in one or both of theprocessors 64A and/or 64B or circuitry (discussed below) associated withthe processors 64A and 64B. For such faults, in various embodiments thesame fault response is applied to the three-terminal power semiconductordevices 42 (FIG. 3A) of both of the inverters 30A and 30B by causing thethree-terminal power semiconductor devices 42 (FIG. 3A) of one of thebanks 40 or 44 of both of the inverters 30A and 30B to short. Becausethe functionality of the processors 64A and 64B is not verifiable insuch fault conditions, it is not verifiable that the processors 64A and64B are able to receive and process information regarding speed of themotors (or back EMF or voltage of the battery 14). As a result, adefault fault action is entailed in such instances. In variousembodiments, that default action is a three-phase short of thethree-terminal power semiconductor devices 42 in one of the banks 44 or40 of both of the inverters 30A and 30B.

In various embodiments and as shown in FIG. 5A AND 5C, the controller 32includes health monitoring circuitry 102 configured to monitor health ofthe processors 64A and 64B via data links 104 and 106, respectively. Insome such embodiments the health monitoring circuitry 102 includes afield programmable gate array (“FPGA”). In such embodiments, the healthmonitoring circuitry 102 may be programmed to perform a safety check,such as a safety handshaking check, and to monitor whether theprocessors 64A and/or 64B are functioning properly (or functioning atall). In some such embodiments, the health monitoring circuitry 102 maybe programmed to implement a rolling counter to perform such monitoringof the processors 64A and 64B. In some such embodiments, the processors64A and 64B also monitor whether the health monitoring circuitry 102 isfunctioning. As such, a fault in the health monitoring circuitry 102 isconsidered to be a fault in circuitry associated with the processors 64Aand 64B.

In various embodiments and as also shown in FIGS. 5A and 5C, thecontroller 32 includes three-phase short circuitry 108. In suchembodiments, the three-phase short circuitry 108 is configured togenerate fault action signals (discussed below) for faults that are notmonitored by the processors 64A and 64B— because the faults may includefaults in the processors 64A and/or 64B and/or the health monitoringcircuitry 102. The fault action signals generated by the three-phaseshort circuitry 108 causes the same fault response to be applied to thethree-terminal power semiconductor devices 42 (FIG. 3A) of both of theinverters 30A and 30B by causing the three-terminal power semiconductordevices 42 (FIG. 3A) of one of the banks 40 or 44 of both of theinverters 30A and 30B to short.

In various embodiments, the three-phase short circuitry 108 is externalto the processors 64A and 64B and is configured to apply a same faultaction to the power inverter 30A and the power inverter 30B for applyingequalized torque to each wheel 16 or 18 operatively coupled to the driveunit 20 responsive to a fault not monitored by the 64A processor or theprocessor 64B. As shown in FIGS. 5A and 5C, the three-phase shortcircuitry 108 is coupled to receive a control signal 110 from the healthmonitoring circuitry 102, a control signal 112 from the processor 64A,and a control signal 114 from the processor 64B. The health monitoringcircuitry 102 is configured to generate the control signal 110responsive to receiving a processor fault indication signal, indicativeof a fault within the processor 64A, from the processor 64A via the datalink 104 or receiving a processor fault indication signal, indicative ofa fault within the processor 64B, from the processor 64B via the datalink 106. The processors 64A and 64B are configured to generate thecontrol signals 112 and 114, respectively, responsive to detectingfailure of the health monitoring circuitry 102 (such as, withoutlimitation, failure of the rolling counter) via the data links 104 and106, respectively.

In various embodiments and as shown in FIG. 5C, the three-phase shortcircuitry 108 includes a voltage regulator 116, a buffer 118, and abuffer 120. In some such embodiments, the voltage regulator 116 includesa voltage regulator configured to convert 12 VDC to 5 VDC. In suchembodiments, the control signals 110, 112, and 114 suitably are 12 VDCsignals. In response to application of any of the 12 VDC control signals110, 112, or 114, the voltage regulator 116 outputs a 5 VDC controlsignal 122. The control signal 122 is input to the buffers 118 and 120.The buffer 118 is coupled to provide the control signal 122 to thedrives 46A2 for the bank 44 of the power inverter 30A. The drives 46A2generate and provide the fault action signal 88′ to the gate terminals48 of the bank 44 of the power inverter 30A, thereby causing thethree-terminal power semiconductor devices 42 of the bank 44 of thepower inverter 30A to short. The buffer 120 is coupled to provide thecontrol signal 122 to the drives 46B2 for the bank 44 of the powerinverter 30B. The drives 46B2 generate and provide the fault actionsignal 92′ to the gate terminals 48 of the bank 44 of the power inverter30B, thereby causing the three-terminal power semiconductor devices 42of the bank 44 of the power inverter 30B to short.

It will be appreciated that shorting the three-terminal powersemiconductor devices 42 of the banks 44 of the inverters 30A and 30B isgiven by way of illustration only and not of limitation. In someembodiments, the three-terminal power semiconductor devices 42 of thebanks 40 of the inverters 30A and 30B are shorted (and thethree-terminal power semiconductor devices 42 of the banks 44 of theinverters 30A and 30B remain open).

Referring additionally to FIG. 5G, in various embodiments anillustrative method 124 is provided for applying a same fault action toa first power inverter and a second power inverter for applyingequalized torque to each wheel operatively coupled to a drive unitresponsive to a fault associated with the first power inverter or thesecond power inverter.

The method 124 begins at a block 126. At a block 128 a fault associatedwith a first power inverter or a second power inverter of a drive unitof an electric vehicle is detected. At a block 130, responsive todetecting the fault, a same fault action is applied to the first powerinverter and the second power inverter for applying equalized torque toeach wheel operatively coupled to the drive unit. The method 124 ends ata block 130.

In various embodiments, a first processor for the first power inverterand a second processor for the second power inverter may monitor for thefault.

In various embodiments, the processor for the inverter with the faultassociated therewith may communicate the fault action to the processorfor the inverter without a fault associated therewith.

In various embodiments, the fault action may include causing all banksof three-terminal power semiconductor devices in the first powerinverter and the second power inverter to open for motor speed less thana threshold speed or causing one bank of three-terminal powersemiconductor devices in the first power inverter and the second powerinverter to short for motor speed greater than the threshold speed.

In various embodiments, the fault associated with a first power inverteror a second power inverter of a drive unit of an electric vehicle mayinclude a fault in a first processor for the first power inverter, or asecond processor for the second power inverter, or health monitoringcircuitry for the first processor and the second processor.

In various embodiments, applying a same fault action to the first powerinverter and the second power inverter for applying equalized torque toeach wheel operatively coupled to the drive unit may include applying,by circuitry external to the first processor and the second processor, asame fault action to the first power inverter and the second powerinverter for applying equalized torque to each wheel operatively coupledto the drive unit.

In various embodiments, the fault action may include causing one bank ofthree-terminal power semiconductor devices in the first power inverterand the second power inverter to short.

Notwithstanding the above, it will be appreciated that in some instancesspeed of one motor may be different from speed of another motor. Forexample, during a turn, an outside wheel might be rotating faster thanan inside wheel. Similarly, wheels may be rotating at different speedsin various wheel slip situations. In some such instances, because theprocessor 64A selects the appropriate speed-dependent fault action forits associated electrical motor 24A and the processor 64B selects theappropriate speed-dependent fault action for its associated electricalmotor 24B, a speed-dependent fault action for one motor of a drive unit20 (for example, based on back EMF and voltage of the battery 14) may bedifferent from a speed-dependent fault action for the other motor of thedrive unit 20.

In addition to the faults associated with the inverters 30A and 30Bdiscussed above, loss of low voltage DC electrical power to thecontroller 32 (such as 12 VDC and referred to herein as 12V) results ina same fault action being applied to both inverters 30A and 30B in orderto help avoid a torque imbalance between the two wheels 16 or 18 drivenby a same drive unit 20.

It will be appreciated that, as shown in FIGS. 5A and 5C, the processors64A and 64B, the drives 46A1, 46A2, 46B1, and 46B2, the healthmonitoring circuitry 102, and the three-phase short circuitry 108 allinclude components that are powered by low voltage DC electrical power(12V) supplied to the controller 32. It will be appreciated that loss of12V supplied to the controller 32 means that the processors 64A and 64B,the drives 46A1, 46A2, 46B1, and 46B2, the health monitoring circuitry102, and the three-phase short circuitry 108 are not available to applya same fault action to both inverters 30A and 30B as discussed above.

Thus, in various embodiments and as discussed below, capability isprovided to apply a same fault action to both inverters 30A and 30B inthe event of loss of 12V supplied to the controller 32.

As shown in FIGS. 5A and 5C and referring additionally to FIGS. 6A-6B,in various embodiments and by way of overview a detection circuit 140 isconfigured to detect loss of low voltage DC electrical power (12V)supplied to the controller 32. A backup power circuit 84A is associatedwith the power inverter 30A and a backup power circuit 84B is associatedwith the power inverter 30B. Each backup power circuit 84A and 84B isconfigured to convert high voltage DC electrical power, such as 450 VDC,to low voltage DC electrical power (such as, for example, a step-downDC-DC converter) responsive to detection of loss of low voltage DCelectrical power supplied to the controller 32. The three-phase shortcircuitry 108 is configured to apply a same fault action to the powerinverter 30A and the power inverter 30B for applying equalized torque toeach wheel 16 or 18 operatively coupled to the drive unit 20 responsiveto detection of loss of low voltage DC electrical power supplied to thecontroller 32.

As shown in FIGS. 5A, 5C, and 6A, in various embodiments the detectioncircuit 140 uses an optocoupler 141 to detect loss of low voltage DCelectrical power (12V) supplied to the controller 32. Low voltage DCelectrical power (such as 12V) is supplied to a resistor R₁ which iselectrically connected in series to a resistor R₂. The resistors R₁ andR₂ function as a voltage divider. A control signal 143 at a suitablevoltage (such as, without limitation 5V) is supplied from a node 145between the resistors R₁ and R₂ to a light-emitting diode (LED) 145 ofthe optocoupler 141. When energized, the LED 145 converts the electricalinput into light and emits light (either visible light or infrared (IR)light). A phototransistor 147 detects the light emitted by the LED 145and turns on. In various embodiments the phototransistor 149 is apull-down transistor. The phototransistor 149 is coupled to provide anenable signal 151 to the backup power circuits 84A and 84B.

During normal operation, the control signal 143 is supplied to the LED147 and the LED 147 emits light. The phototransistor 149 detects thelight and turns on. Because the phototransistor 149 is a pull-downtransistor, the enable signal 151 is low when the phototransistor 149 ison. When the enable signal 151 is low, the enable signal 151 pulls downthe backup power circuits 84A and 84B (such as step-down DC-DCconverters) such that the backup power circuits 84A and 84B are turnedoff and are prevented from applying a three-phase short.

In the event of loss of low voltage DC electrical power (12V), thesignal 143 goes away and the LED 147 stops emitting light. As a result,the phototransistor 149 turns off and the enable signal 151 is high.When the enable signal 151 is high, the backup power circuits 84A and84B are turned on and apply a three-phase short as described below. Forexample, the enable signal 151 may turn on a step-down DC-DC converterin each of the backup power circuits 84A and 84B to convert high voltageDC electrical power to low voltage DC electrical power (12V).

In various embodiments the gate drive circuit 46A and the gate drivecircuit 46B include the backup power circuits 84A and 84B, respectively.High voltage DC electrical power (such as 450V) is provided to each ofthe backup power circuits 84A and 84B. Each backup power circuit 84A and84B is configured to convert 450V DC electrical power to low voltage DCelectrical power, such as 12 VDC electrical power. As such, the backuppower circuits 84A and 84B suitably include a step-down DC-DC converter(as discussed above), voltage divider circuitry (as discussed below) ifdesired, or the like.

As shown in FIG. 6B, if desired, in some embodiments each backup powercircuit 84A and 84B may optionally include a normally-open relay 152having a relay coil 154 operably coupled to receive low voltage DCelectrical power (12V) from the controller 32. In such embodiments thenormally-open relay 152 also includes a normally-open contact 156. Asdiscussed above, during normal operation low voltage DC electrical power12V is provided to the relay coil 154 and the relay coil 154 isenergized, thereby causing the normally-open contact 156 to open). Inthe event of loss of low voltage DC electrical power (12V), the relaycoil 154 is de-energized, thereby causing the normally-open contact 156to shut). Thus, in such embodiments, the detection circuit 140 suitablyincludes the relay coil 154 and the low voltage DC electrical power(12V) from the controller 32 may be considered to be a control signal.

In such embodiments, each backup power circuit 84A and 84B suitablyincludes a voltage divider 158 operably coupled to receive the highvoltage DC electrical power. The voltage divider 158 is configured toconvert the high voltage DC electrical power to the low voltage DCelectrical power and is further configured to output the low voltage DCelectrical power to the normally-open contact 156. In such embodiments,during normal operation (when low voltage DC electrical power isprovided to the relay coil 154 and the normally-open contact 156 isopen), the backup power circuits 84A and 84B do not provide 12Velectrical power. Conversely, in the event of loss of low voltage DCelectrical power (12V) (when the relay coil 154 is de-energized and thenormally-open contact 156 is shut), the backup power circuits 84A and84B provide 12V electrical power. Thus, in such embodiments, each backuppower circuit 84A and 84B also suitably includes the normally-opencontact 156.

As discussed above, in various embodiments the power inverter 30A andthe power inverter 30B each include two banks 40 and 44 of thethree-terminal power semiconductor devices 42. As discussed below, thethree-phase short circuitry 108 is further configured to cause one bank40 or 44 of the three-terminal power semiconductor devices 42 in thepower inverter 30A and the power inverter 30B to short responsive todetection of loss of low voltage DC electrical power supplied to thecontroller 32.

As shown in FIGS. 5A and 5C, regardless of how loss of low voltage DCelectrical power (12V) is detected and how the low voltage DC electricalpower (12V) is generated by the backup power circuits 84A and 84B, thelow voltage DC electrical power (12V) is supplied from the backup powercircuits 84A and 84B to the voltage regulator 116. In response toapplication of the low voltage DC electrical power (12V), the voltageregulator 116 outputs a 5 VDC control signal 122. The control signal 122is input to the buffers 118 and 120. The buffer 118 is coupled toprovide the control signal 122 to the drives 46A2 for the bank 44 of thepower inverter 30A. The drives 46A2 generate and provide the faultaction signal 88′ to the gate terminals 48 of the bank 44 of the powerinverter 30A, thereby causing the three-terminal power semiconductordevices 42 of the bank 44 of the power inverter 30A to short. The buffer120 is coupled to provide the control signal 122 to the drives 46B2 forthe bank 44 of the power inverter 30B. The drives 46B2 generate andprovide the fault action signal 92′ to the gate terminals 48 of the bank44 of the power inverter 30B, thereby causing the three-terminal powersemiconductor devices 42 of the bank 44 of the power inverter 30B toshort.

It will be appreciated that shorting the three-terminal powersemiconductor devices 42 of the banks 44 of the inverters 30A and 30B isgiven by way of illustration only and not of limitation. In someembodiments, the three-terminal power semiconductor devices 42 of thebanks 40 of the inverters 30A and 30B are shorted (and thethree-terminal power semiconductor devices 42 of the banks 44 of theinverters 30A and 30B remain open).

In various embodiments and as shown in FIG. 6C, a method 160 is providedfor applying a same fault action to both inverters of a drive unit of anelectric vehicle in the event of loss of 12V supplied to a commoncontroller for both inverters.

The method 160 starts at a block 162. At a block 164, loss of lowvoltage direct current (DC) electrical power supplied to a controllerfor a first processor for a first power inverter and a second processorfor a second power inverter of a drive unit for an electric vehicle isdetected. At a block 166 high voltage DC electrical power is convertedto low voltage DC electrical power responsive to detection of loss oflow voltage DC electrical power supplied to the controller. At a block168 a same fault action is applied to the first power inverter and thesecond power inverter for applying equalized torque to each wheeloperatively coupled to the drive unit responsive to detection of loss oflow voltage DC electrical power supplied to the controller. The method160 stops at a block 170.

In various embodiments a control signal may be provided responsive topresence of low voltage DC electrical power supplied to the controller.

In various embodiments applying a same fault action to the first powerinverter and the second power inverter for applying equalized torque toeach wheel operatively coupled to the drive unit responsive to detectionof loss of low voltage DC electrical power supplied to the controllermay include applying a same fault action to the first power inverter andthe second power inverter for applying equalized torque to each wheeloperatively coupled to the drive unit responsive to absence of thecontrol signal.

In various embodiments the fault action may include causing one bank ofthree-terminal power semiconductor devices in the first power inverterand the second power inverter to short.

Those skilled in the art will recognize that at least a portion of thedevices and/or processes described herein can be integrated into a dataprocessing system. Those having skill in the art will recognize that adata processing system generally includes one or more of a system unithousing, a video display device, memory such as volatile or non-volatilememory, processors such as microprocessors or digital signal processors,computational entities such as operating systems, drivers, graphicaluser interfaces, and applications programs, one or more interactiondevices (e.g., a touch pad, a touch screen, an antenna, etc.), and/orcontrol systems including feedback loops and control motors (e.g.,feedback for sensing position and/or velocity; control motors for movingand/or adjusting components and/or quantities). A data processing systemmay be implemented utilizing suitable commercially available components,such as those typically found in data computing/communication and/ornetwork computing/communication systems.

The term module, as used in the foregoing/following disclosure, mayrefer to a collection of one or more components that are arranged in aparticular manner, or a collection of one or more general-purposecomponents that may be configured to operate in a particular manner atone or more particular points in time, and/or also configured to operatein one or more further manners at one or more further times. Forexample, the same hardware, or same portions of hardware, may beconfigured/reconfigured in sequential/parallel time(s) as a first typeof module (e.g., at a first time), as a second type of module (e.g., ata second time, which may in some instances coincide with, overlap, orfollow a first time), and/or as a third type of module (e.g., at a thirdtime which may, in some instances, coincide with, overlap, or follow afirst time and/or a second time), etc. Reconfigurable and/orcontrollable components (e.g., general purpose processors, digitalsignal processors, field programmable gate arrays, etc.) are capable ofbeing configured as a first module that has a first purpose, then asecond module that has a second purpose and then, a third module thathas a third purpose, and so on. The transition of a reconfigurableand/or controllable component may occur in as little as a fewnanoseconds, or may occur over a period of minutes, hours, or days.

In some such examples, at the time the component is configured to carryout the second purpose, the component may no longer be capable ofcarrying out that first purpose until it is reconfigured. A componentmay switch between configurations as different modules in as little as afew nanoseconds. A component may reconfigure on-the-fly, e.g., thereconfiguration of a component from a first module into a second modulemay occur just as the second module is needed. A component mayreconfigure in stages, e.g., portions of a first module that are nolonger needed may reconfigure into the second module even before thefirst module has finished its operation. Such reconfigurations may occurautomatically, or may occur through prompting by an external source,whether that source is another component, an instruction, a signal, acondition, an external stimulus, or similar.

For example, a central processing unit of a personal computer may, atvarious times, operate as a module for displaying graphics on a screen,a module for writing data to a storage medium, a module for receivinguser input, and a module for multiplying two large prime numbers, byconfiguring its logical gates in accordance with its instructions. Suchreconfiguration may be invisible to the naked eye, and in someembodiments may include activation, deactivation, and/or re-routing ofvarious portions of the component, e.g., switches, logic gates, inputs,and/or outputs. Thus, in the examples found in the foregoing/followingdisclosure, if an example includes or recites multiple modules, theexample includes the possibility that the same hardware may implementmore than one of the recited modules, either contemporaneously or atdiscrete times or timings. The implementation of multiple modules,whether using more components, fewer components, or the same number ofcomponents as the number of modules, is merely an implementation choiceand does not generally affect the operation of the modules themselves.Accordingly, it should be understood that any recitation of multiplediscrete modules in this disclosure includes implementations of thosemodules as any number of underlying components, including, but notlimited to, a single component that reconfigures itself over time tocarry out the functions of multiple modules, and/or multiple componentsthat similarly reconfigure, and/or special purpose reconfigurablecomponents.

In some instances, one or more components may be referred to herein as“configured to,” “configured by,” “configurable to,” “operable/operativeto,” “adapted/adaptable,” “able to,” “conformable/conformed to,” etc.Those skilled in the art will recognize that such terms (for example“configured to”) generally encompass active-state components and/orinactive-state components and/or standby-state components, unlesscontext requires otherwise.

While particular aspects of the present subject matter described hereinhave been shown and described, it will be apparent to those skilled inthe art that, based upon the teachings herein, changes and modificationsmay be made without departing from the subject matter described hereinand its broader aspects and, therefore, the appended claims are toencompass within their scope all such changes and modifications as arewithin the true spirit and scope of the subject matter described herein.It will be understood by those within the art that, in general, termsused herein, and especially in the appended claims (for example, bodiesof the appended claims) are generally intended as “open” terms (forexample, the term “including” should be interpreted as “including butnot limited to,” the term “having” should be interpreted as “having atleast,” the term “includes” should be interpreted as “includes but isnot limited to,” etc.). It will be further understood by those withinthe art that if a specific number of an introduced claim recitation isintended, such an intent will be explicitly recited in the claim, and inthe absence of such recitation no such intent is present. For example,as an aid to understanding, the following appended claims may containusage of the introductory phrases “at least one” and “one or more” tointroduce claim recitations. However, the use of such phrases should notbe construed to imply that the introduction of a claim recitation by theindefinite articles “a” or “an” limits any particular claim containingsuch introduced claim recitation to claims containing only one suchrecitation, even when the same claim includes the introductory phrases“one or more” or “at least one” and indefinite articles such as “a” or“an” (for example, “a” and/or “an” should typically be interpreted tomean “at least one” or “one or more”); the same holds true for the useof definite articles used to introduce claim recitations. In addition,even if a specific number of an introduced claim recitation isexplicitly recited, those skilled in the art will recognize that suchrecitation should typically be interpreted to mean at least the recitednumber (for example, the bare recitation of “two recitations,” withoutother modifiers, typically means at least two recitations, or two ormore recitations). Furthermore, in those instances where a conventionanalogous to “at least one of A, B, and C, etc.” is used, in generalsuch a construction is intended in the sense one having skill in the artwould understand the convention (for example, “a system having at leastone of A, B, and C” would include but not be limited to systems thathave A alone, B alone, C alone, A and B together, A and C together, Band C together, and/or A, B, and C together, etc.). It will be furtherunderstood by those within the art that typically a disjunctive wordand/or phrase presenting two or more alternative terms, whether in thedescription, claims, or drawings, should be understood to contemplatethe possibilities of including one of the terms, either of the terms, orboth terms unless context dictates otherwise. For example, the phrase “Aor B” will be typically understood to include the possibilities of “A”or “B” or “A and B.”

The foregoing detailed description has set forth various embodiments ofthe devices and/or processes via the use of block diagrams, flowcharts,and/or examples. Insofar as such block diagrams, flowcharts, and/orexamples contain one or more functions and/or operations, it will beunderstood by those within the art that each function and/or operationwithin such block diagrams, flowcharts, or examples can be implemented,individually and/or collectively, by a wide range of hardware, software(e.g., a high-level computer program serving as a hardwarespecification), firmware, or virtually any combination thereof, limitedto patentable subject matter under 35 U.S.C. 101. In an embodiment,several portions of the subject matter described herein may beimplemented via Application Specific Integrated Circuits (ASICs), FieldProgrammable Gate Arrays (FPGAs), digital signal processors (DSPs), orother integrated formats. However, those skilled in the art willrecognize that some aspects of the embodiments disclosed herein, inwhole or in part, can be equivalently implemented in integratedcircuits, as one or more computer programs running on one or morecomputers (e.g., as one or more programs running on one or more computersystems), as one or more programs running on one or more processors(e.g., as one or more programs running on one or more microprocessors),as firmware, or as virtually any combination thereof, limited topatentable subject matter under 35 U.S.C. 101, and that designing thecircuitry and/or writing the code for the software (e.g., a high-levelcomputer program serving as a hardware specification) and or firmwarewould be well within the skill of one of skill in the art in light ofthis disclosure. In addition, those skilled in the art will appreciatethat the mechanisms of the subject matter described herein are capableof being distributed as a program product in a variety of forms, andthat an illustrative embodiment of the subject matter described hereinapplies regardless of the particular type of signal bearing medium usedto actually carry out the distribution. Examples of a signal bearingmedium include, but are not limited to, the following: a recordable typemedium such as a floppy disk, a hard disk drive, a Compact Disc (CD), aDigital Video Disk (DVD), a digital tape, a computer memory, etc.; and atransmission type medium such as a digital and/or an analogcommunication medium (e.g., a fiber optic cable, a waveguide, a wiredcommunications link, a wireless communication link (e.g., transmitter,receiver, transmission logic, reception logic, etc.), etc.).

With respect to the appended claims, those skilled in the art willappreciate that recited operations therein may generally be performed inany order. Also, although various operational flows are presented in asequence(s), it should be understood that the various operations may beperformed in other orders than those which are illustrated or may beperformed concurrently. Examples of such alternate orderings may includeoverlapping, interleaved, interrupted, reordered, incremental,preparatory, supplemental, simultaneous, reverse, or other variantorderings, unless context dictates otherwise. Furthermore, terms like“responsive to,” “related to,” or other past-tense adjectives aregenerally not intended to exclude such variants, unless context dictatesotherwise.

While the disclosed subject matter has been described in terms ofillustrative embodiments, it will be understood by those skilled in theart that various modifications can be made thereto without departingfrom the scope of the claimed subject matter as set forth in the claims.

What is claimed is:
 1. A controller comprising: one or more processorsassociated with a first and second power inverter for a drive unit foran electric vehicle; and one or more computer-readable media for the oneor more processors, each being configured to store computer-executableinstructions configured to cause its associated processor to apply asame fault action to the first power inverter and the second powerinverter responsive to a fault associated with an inverter chosen fromthe first power inverter and the second power inverter, wherein the samefault action includes applying equalized torque to each axle operativelycoupled to the drive unit; wherein the computer-executable instructionsare further configured to cause its associated processor to monitor forthe fault; wherein the fault action further includes an action chosenfrom causing all of a plurality of banks of three-terminal powersemiconductor devices in the first power inverter and the second powerinverter to open when motor speed is less than a threshold speed andcausing one bank of three-terminal power semiconductor devices in eachof the first power inverter and the second power inverter to short whenmotor speed is greater than the threshold speed.
 2. The controller ofclaim 1, further comprising a communications link, wherein the one ormore processors includes a first processor associated with the firstpower inverter for the drive unit and a second processor associated withthe second power inverter, and the communications link is between thefirst processor and the second processor.
 3. The controller of claim 2,further comprising three-phase short circuitry external to the firstprocessor and the second processor and configured to apply a same faultaction to the first power inverter and the second power inverterresponsive to a fault not monitored by the first processor and thesecond processor, wherein the same fault action includes applyingequalized torque to each axle operatively coupled to the drive unit. 4.The controller of claim 3, further comprising health monitoringcircuitry configured to monitor health of the first processor and thesecond processor.
 5. The controller of claim 4, wherein: the faultincludes a fault chosen from a fault in a processor chosen from thefirst processor and the second processor and a fault in the healthmonitoring circuitry; and the three-phase short circuitry is furtherconfigured to cause one bank of three-terminal power semiconductordevices in the first power inverter and the second power inverter toshort responsive to the fault chosen from a fault in a processor chosenfrom the first processor and the second processor and the fault in thehealth monitoring circuitry.
 6. A dual power inverter module comprising:a DC link capacitor electrically connectable to a source of high voltagedirect current (DC) electrical power; a first power inverterelectrically connectable to the DC link capacitor and configured toconvert high voltage DC electrical power to three phase high voltagealternating current (AC) electrical power, the first power inverterbeing further configured to supply the three phase high voltage ACelectrical power to a first electric motor; a second power inverterelectrically connectable to the DC link capacitor and configured toconvert high voltage DC electrical power to three phase high voltage ACelectrical power, the second power inverter being further configured tosupply the three-phase high voltage AC electrical power to a secondelectric motor; and a controller including: one or more processorsassociated with a first and second power inverter for a drive unit foran electric vehicle; and one or more computer-readable media for the oneor more processors, each being configured to store computer-executableinstructions configured to cause its associated processor to apply asame fault action to the first power inverter and the second powerinverter responsive to a fault associated with an inverter chosen fromthe first power inverter and the second power inverter, wherein the samefault action includes applying equalized torque to each axle operativelycoupled to the drive unit; wherein the computer-executable instructionsare further configured to cause its associated processor to monitor forthe fault; wherein the fault action further includes an action chosenfrom causing all of a plurality of banks of three-terminal powersemiconductor devices in the first power inverter and the second powerinverter to open when motor speed is less than a threshold speed andcausing one bank of three-terminal power semiconductor devices in eachof the first power inverter and the second power inverter to short whenmotor speed is greater than the threshold speed.
 7. The module of claim6, further comprising a communications link, wherein the one or moreprocessors includes a first processor associated with the first powerinverter for the drive unit and a second processor associated with thesecond power inverter, and the communications link is between the firstprocessor and the second processor.
 8. The module of claim 7, furthercomprising three-phase short circuitry external to the first processorand the second processor and configured to apply a same fault action tothe first power inverter and the second power inverter responsive to afault not monitored by the first processor and the second processor,wherein the same fault action includes applying equalized torque to eachaxle operatively coupled to the drive unit.
 9. The module of claim 8,further comprising health monitoring circuitry configured to monitorhealth of the first processor and the second processor.
 10. The moduleof claim 9, wherein: the fault includes a fault chosen from a fault in aprocessor chosen from the first processor and the second processor and afault in the health monitoring circuitry; and the three-phase shortcircuitry is further configured to cause one bank of three-terminalpower semiconductor devices in the first power inverter and the secondpower inverter to short responsive to the fault chosen from a fault in aprocessor chosen from the first processor and the second processor andthe fault in the health monitoring circuitry.
 11. An electric vehiclecomprising: a vehicle body; a high voltage direct current (DC)electrical battery disposed within the vehicle body; first and secondelectric motors mechanically couplable to rotate at least one set ofaxles; and at least one dual power inverter module including: a DC linkcapacitor electrically connectable to the high voltage DC electricalbattery; a first power inverter electrically connectable to the DC linkcapacitor and configured to convert high voltage DC electrical power tothree phase high voltage alternating current (AC) electrical power, thefirst power inverter being further configured to supply the three phasehigh voltage AC electrical power to an electric motor chosen from thefirst and second electric motors; a second power inverter electricallyconnectable to the DC link capacitor and configured to convert highvoltage DC electrical power to three phase high voltage AC electricalpower, the second power inverter being further configured to supply thethree-phase high voltage AC electrical power to the other electric motorchosen from the first and second electric motors; and a commoncontroller electrically connectable to the first power inverter and thesecond power inverter, the common controller being configured to controlthe first power inverter and the second power inverter, the commoncontroller including: one or more processors associated with the firstand second power inverter; and one or more computer-readable media forthe one or more processors each being configured to storecomputer-executable instructions configured to cause its associatedprocessor to apply a same fault action to the first power inverter andthe second power inverter responsive to a fault associated with aninverter chosen from the first power inverter and the second powerinverter, wherein the same fault action includes applying equalizedtorque to each axle operatively coupled to the drive unit; wherein thecomputer-executable instructions are further configured to cause itsassociated processor to monitor for the fault; wherein the fault actionfurther includes an action chosen from causing all of a plurality banksof three-terminal power semiconductor devices in the first powerinverter and the second power inverter to open for motor speed less thana threshold speed and causing one bank of three-terminal powersemiconductor devices in each of the the first power inverter and thesecond power inverter to short when motor speed is greater than thethreshold speed.
 12. The vehicle of claim 11, further comprising acommunications link, wherein the one or more processors includes a firstprocessor associated with the first power inverter for the drive unitand a second processor associated with the second power inverter, andthe communications link is between the first processor and the secondprocessor.
 13. The vehicle of claim 12, further comprising three-phaseshort circuitry external to the first processor and the second processorand configured to apply a same fault action to the first power inverterand the second power inverter responsive to a fault not monitored by thefirst processor and the second processor, wherein the one or moreprocessors includes a first processor associated with the first powerinverter for the drive unit and a second processor associated with thesecond power inverter, and the communications link is.
 14. The vehicleof claim 13, further comprising health monitoring circuitry configuredto monitor health of the first processor and the second processor,wherein: the fault includes a fault chosen from a fault in a processorchosen from the first processor and the second processor and a fault inthe health monitoring circuitry; and the three-phase short circuitry isfurther configured to cause one bank of three-terminal powersemiconductor devices in the first power inverter and the second powerinverter to short responsive to the fault chosen from a fault in aprocessor chosen from the first processor and the second processor andthe fault in the health monitoring circuitry.